A powerful package!
The new EGC electric axis – as a
spindle or toothed belt axis – is setting
new standards for power, dynamics,
precision and smooth running. For
loads up to 400 kg and strokes up
to 8500 mm – try it for yourself!

www.festo.com

Solid as a Rock
Dear reader,
Difficult times are the ultimate test of a solid relationship â&#x20AC;&#x201C; in
business life as well as in private life. So now is a good time
to review your partners in the supply chain, to evaluate their
performance with respect to their stability, their ability to keep
promises but also their flexibility to adapt to a changing environment. How are we doing as Festo? Tell us so we can improve
further.

Dr. Ansgar Kriwet, Member of the
Management Board Region and Sales Europe

The economic downturn requires more cooperation, because
resources in all groups and companies are strained and big challenges must be addressed. Improvements are urgently needed.
Improvements in efficiency along the entire process chain, from
the selection of the right automation components in engineering
up to stock management in the warehouse. You will find some
ideas on how to increase efficiency in all of these areas further
on in this issue. The importance of effectiveness also comes into
focus. Improving machine performance, adding real value that
the customer can count and feel is a must, and innovation is the
key to that. So it is no surprise that in these challenging times
the application engineering department of Festo is in great demand. Many companies are using the current reduced operational workload to redesign their machines for higher performance. Festo is participating in many such projects, adding our
know-how of automation to the know-how of processes of our
customers.
However, such cooperation always requires one important prerequisite: trust. You need the trust that your partners are really
adding value to the partnership, that they are reliable and financially stable enough to survive, that they are interested in the
long-term benefit of both sides and not just in a quick return
for themselves. Such partners are not always easy to find. At
Festo, we believe in this kind of partnership, it is what has made
us successful. As a family-owned company, we think in generations and not in quarterly results. We believe that making you
successful is our best option for the future. We believe in partnership, especially in these difficult times.
In stormy weather, the advantage of a professional team where
everyone can blindly trust one another is even more evident.
LetÂ´s work together to catch the recovery wave!
Yours,

Ansgar Kriwet

Photograph: stockmaritime.com/Loic Jacob

In Focus Trust and cooperation are vital in order to
stay on course, and not only on the high seas. In industry partnerships are also becoming increasingly
important. This means that projects which cannot
be managed by one company can still be realised.
In this edition of “trends in automation”, you will
find descriptions of trends and expert opinions on
this subject as well as many examples of successful
partnerships.

Bionics live: nature was the model
for the development of the FinGripper.

Compass

10

“Partners share risks and operate
without a hierarchy.”

Inspiration
In Focus Achieving more together
Prof. Engelbert Westkämper, Head of
the Fraunhofer Institute of Production
Technology and Automation (IPA) in
Stuttgart, discusses the opportunities
and possibilities offered by partnerships
in industry. 10

In Focus Close cooperation for innovation
Studies show that development partnerships are well worthwhile: they help to
reduce costs and safeguard technological
advances. 14
Wings, fins and flexibility
Bionic principles open up completely
new possibilities in automation technology, as the latest developments by Festo
show. 16

2.2009 trends in automation
Contents 4 5
–

24

Accessories offer large
savings potential.

Impulse
Clever combinations
Mechatronic Motion Solutions combines
pneumatic, electrical and servopneumatic
components. The result is smooth production runs and easy cost calculations. 20
In Focus Cutting the cost of accessories
A partnership-based logistics solution
helps Festo to help its customer optimise
their component stock levels and reduce
costs. 24
Step by step to greater safety
The new EU Machinery Directive comes
into force at the end of the year. In Part 2
of our series “Safety technology” you
will find ideas for implementing many
safety functions. 26
In Focus Beneffiting from a partner
during a crisis
With Festo as their partner, customers
can optimise their business processes
and save money. Ten examples of best
practices. 30

40

Tripod units provide dynamic handling
and take up little space.

Synergies
In Focus Small country – great efficiency
The Netherlands is among the world’s
largest agricultural exporters. This is all
made possible by the latest automation
technology. 32

In Focus Smart partnerships
Festo provided an expanded VTSA valve
terminal to help Beck Automation AG with
the development of a handling robot for
an in-mould labelling machine. 38

Stronger than before
Two Indian machine builders are using
the credit crunch as an opportunity for
growth. Technology from Festo plays a
major role. 36

The Millau Viaduct across the Tarn Valley in the south of
France is without doubt one of the most impressive structures in Europe. It is the result of successful long-term partnerships, ranging from the design by the British architect
Lord Norman Foster to the expertise of the suppliers and
contractors and the labour of hundreds of workers from all
kinds of trades. With a length of 2460 metres and a height
of 270 metres, it is the longest and highest cable-stayed road
bridge in the world and took more than 2.2 million working
hours to build.

Photograph: Foster + Partners, Stephane Compoint

2.2009 trends in automation
Panorama 6 7
â&#x20AC;&#x201C;

www.festo.com/innovations
Valves

Compact and with a high flow rate
The compact solenoid valve VOVG with high flow rates can be
used everywhere, whether for compact handling applications
or for solutions demanding an extremely high installation density. It also displays its strengths in applications in the electronics or light assembly industries, for example those requiring
high cylinder speeds together with a low minimum operating
pressure achieved through high-performance dimensioning.
The solenoid valves in the valve range VOVG are available as
single valves or for manifold assembly with a wide choice of
functions. Its space-saving design enables direct on-site installation, thus reducing the amount of tubing required and boosting system efficiency. The cartridge seal system and spool
principle provide a long service life and ensure high system
availability. And what’s more, the VOVG can also be produced in
application-specific variants.

Optimised for minimal
installation space: solenoid
valve VOVG.

Electric drives

Ideal for standard applications
The new electric toothed belt axis ELGR is
intended for use in automation applications with comparatively modest demands regarding load capacity, dynamics
and precision. Its cost-optimised design
and easy-to-use end-position sensing for
high operational safety open up a broad
range of applications with a very good
price/performance ratio.
The dimensioning software “PositioningDrives” and the configuration software
FCT enable fast commissioning of this
complete solution. The open motor interface means that the axis can be connected not only to Festo motors but also
to those by other manufacturers. One
long slide and up to two extra slides can
be used when a higher load capacity and
more precise guidance characteristics are
required.

Pre-assembled emergency stop control unit
The EU Machinery Directive comes into force on 29 December 2009. It will
affect not only machine builders of pneumatic systems but everyone who
expands or modernises pneumatic installations or repairs them using nonoriginal spare parts. Festo is offering a pre-assembled emergency stop
control unit for stand-alone operation within a network. The unit makes
it possible to activate a safety valve MS6-SV independently, link in emergency-stop command units and connect a light barrier or door protection
switch. This mechatronic system conforms to DIN ES ISO 13849-1 and
offers the following:
• Protection against unexpected start-up
• Category 4 safe exhaust function
• High performance level PL = e (SIL 3) in risk assessments

Category 4 safe exhaust function and protection against unexpected start-up are provided by this pre-assembled emergencystop control unit.

Valve terminals

Flexible and
modular

Valve terminals

Measuring relative or differential
pressures
There is often a need to measure and
evaluate pressures in process and factory
automation. Both can be done with the
new analogue input module CPX-4AE-P,
designed for use with the CPX terminal.
Instead of using costly external sensors,
which take up space and involve additional installation time, all that’s needed
is a 4 mm tube between the measuring
point and the pressure sensor module.
The module offers integrated functions
to IP65/67 and has several benefits, such
as simple parameterisation, fast commissioning, and evaluation as absolute values in mbar, psi or kPa without conversion.

Flexible for use with individual sub-bases: the
modular valve terminal MPA-L.

Up to 32 valves size MPA1 with flow rates
of up to 360 l/min. can now be fitted on
a valve terminal MPA-L. Its very light and
corrosion-resistant sub-bases are made
of plastic and can be used individually or
combined in groups of 4. The valves can
be actuated via multi-pin plug connectors
or the CPX installation system for fieldbuses.

Achieving more
together
True professionals when it comes to networks and partnerships – the experts of the
Fraunhofer Institute of Production Technology and Automation, in short the Fraunhofer IPA,
located in Stuttgart, Germany, prove their worth every day. Prof. Engelbert Westkämper is
the Head of the Institute, which is involved in around 300 development partnerships at any
one time. In this interview, Prof. Westkämper explains why more progress can be made by
working with a suitable partner than alone, and why partnerships in the automotive industry are not necessarily applicable as models for the machine construction sector.

trends in automation: Professor Westkämper, what are the
characteristics of successful partnerships?
Prof. Engelbert Westkämper: In general, companies form partnerships in order to exploit particular competencies in the development and production of innovative products for the benefit
of both sides. They enjoy the advantages that synergies can
bring. The sign of especially successful partnerships is the creation of products and technical systems which could not have
been achieved by one company alone, as special know-how is
required in order to overcome the obstacles facing us nowadays.
Partners share risks and operate without a hierarchy.
The automotive industry shows us how this can be done.
OEMs increasingly require their suppliers to supply complete
modules and systems directly to the assembly lines of vehicle
manufacturers. Can this also be the future of machine and plant
construction?
Westkämper: I am not sure that the partnerships and networks
in the automotive industry can be a model for the machine construction industry. In machine construction the solutions are
generally customer-specific and require close cooperation between the partners at the design stage. This means that trust

and reliability play a very large part in every project. The high
level of individual solutions together with the small quantities
involved demand flexibility and adaptability. I believe that partnerships in the machine construction industry are more like relationships between neighbours in which each partner supports
the other to the best of their abilities and avoid exploitation.
What partnership or networking project are you most concerned with at the moment?
Westkämper: At the moment, we are working hard to compete
successfully in a competition organised by the German Federal
Ministry of Education and Research (BMBF) to encourage partnerships and innovation between science and business. We are
striving to create a new generation of machines and a new type
of production system which will be characterised by technical
intelligence as well as machines and an organisational structure
that are capable of learning. Taking the motto of “Knowledge
to Create Value and Safeguard Long-Term Production”, some
30 companies in the field of machine construction have already
joined this project. The result is a regional network which has
set itself the ambitious target of developing and marketing the
factories of the future on a partnership basis. With our newly
founded association, “Manufuture BW”, we would like to initi-

2.2009 trends in automation
Inspiration 10 11
–

Personal data

Prof. Dr.-Ing. Engelbert
Westkämper
Engelbert Westkämper studied mechanical engineering at
the University of Technology in Aachen (RWTH). After completing his degree, he spent the next eleven years as head
of the Production Technology department of the MBB Commercial Aviation Division and of the central Production Technology department at AEG. In 1988, Westkämper accepted
a position as professor and head of the Institute of Machine
Tools and Production Technology at the Technical University
of Braunschweig. Since 1995, Prof. Westkämper, together
with Prof. Alexander Verl, has been joint head of the Fraunhofer Institute of Production Technology and Automation
(IPA) in Stuttgart and a professor and director of the Institute
of Industrial Production and Factory Management (IFF) at the
University of Stuttgart.

The Institute

Fraunhofer IPA and IFF,
University of Stuttgart
With a research budget of 1.4 billion euros, 57 institutes
in 40 locations across Germany and 15,000 staff, the
Fraunhofer Gesellschaft is the leading organisation for
applied research in Europe. The clients of the individual
institutes are industrial companies, service providers and
public sector organisations.
The Fraunhofer IPA in Stuttgart has 250 staff and conducts
application-related research into corporate organisation,
automation and surface treatment technology. Its subject
areas cover 14 departments and range from digital factories, robotic systems, clean-room and micro production
through to orthopaedics.
Located on the same site is the Institute of Industrial Production and Factory Management (IFF) of the University
of Stuttgart, a partner institute of the IPA. It has a staff of
40 and conducts both pure research and application-oriented projects, such as its Learning Factory for Advanced
Industrial Engineering. The IFF handles projects on subjects such as versatility in production systems, life cycle
management, the digital factory, microsystem and nano
technology and modelling and simulation.
The iFactory learning factory from Festo Didactic at the IFF, University of Stuttgart. In the aIE learning factory, equipped with a
physical production system and digital learning terminal, managers
and production and logistics planners learn how to design flexible
and versatile assembly lines.

ate developments in production technology that will be
recognised worldwide.
You are currently participating in the “Manufuture” network.
What are the aims of the partners in this network?
Manufuture is a European technology platform which aims to
bring production research in Europe back up to a level appropriate to the economic importance of European industry. We
have already achieved quite a lot through working with industrial companies and associations. Companies hope that this
project will generate ideas for their own developments which
will lead to greater competitiveness and safeguard the longterm future of their production operations. Many partners hope
that Manufuture will produce practical innovations, not only because of pressure from European legislation but also because
they recognise that greater efficiency means competitive advantages. In our various preparatory discussions, we noticed great
enthusiasm for subjects such as energy saving and intelligent
production systems. At the same time, many partners regret the
fact that it takes a long time to progress from ideas to concrete
projects. In order to reduce this, we have founded a European research association called EFFRA (European Factory of the Future
Research Association), which a number of leading companies in

the state of Baden-Württemberg have already joined. Festo has
played a major role in planning the strategies and initiatives
right from the beginning.
Ideally, what form should a partnership between customers
and suppliers take?
Westkämper: Ideally, a partnership should be characterised by
mutual trust and the will to develop something unique and new.
Partners should foster a climate of innovation and technical creativity. Together, partners can achieve far more than as individuals. If partnerships also encompass the necessary breadth and
depth of technological know-how, the partners will have nothing
to fear from global competition.
In the course of your career, you have not always worked in
research and teaching. How does your industrial experience during your time with MBB and AEG benefit you now? Were partnerships also important during that period?
Westkämper: Ten years of working in industry provided me with
a good basis for understanding problems and evaluating the
potential of innovations. I also developed a feeling for what is
possible despite widely-held ideas to the contrary. You cannot

2.2009 trends in automation
Inspiration 12 – 13

“Solutions in machine
construction are typically
customer-specific – trust
and reliability play an
important part in the
relationship between
partners.”
Engelbert Westkämper

acquire this experience in the academic field. With both companies, I worked in the field of production technology. This enabled
me to build up a broad base of knowledge about production
technology and business management which is still very valuable, even today.
A personal question: who or what inspires you in your work?
Westkämper: The large measure of freedom which I have and
the opportunity to work with young engineers, who are always
enthusiastic about new things, make my work enjoyable, despite the heavy burden of my numerous responsibilities at the
University of Stuttgart and the Fraunhofer IPA.
Finally, a question about your private life: what do you do in
your free time, do you have particular hobbies?
Westkämper: My hobbies are hiking, cycling and reading. Unfortunately, I have very little time for any of these!

In Focus Innovation partnerships

Close cooperation for innovation
At a time when all costs are being critically examined, research and development budgets
are also coming under pressure. It is therefore no surprise that more and more OEMs are
working with expert from among their suppliers in order to develop innovations. This allows
costs to be reduced while ensuring that companies do not miss out on new technologies.

I

n many companies today, the conflict
between the need to innovate and to
reduce costs is sharper than ever before. On the one hand, consumers
are less willing to forego the latest technological developments, while on the
other, many R&D budgets have been
heavily cut back as a result of the credit
crunch. One way out of this problem, and
one which is being increasingly followed
in many areas of the mechanical engineering industry – particularly the automotive industry – is development or innovation partnerships. This means that
know-how and resources can be concentrated and results made available quicker.
What is the current situation with such
cooperation models? What kinds of partners are preferred and how will the trend
continue in the years to come? A study
has provided some interesting answers.
Who is working with whom?
The study showed, for example, that partnerships are mainly formed between companies who are already in a customer/
supplier relationship. In addition, the
major form of partnership is one which
aims to optimise or restructure production processes, while up to now there
has been less demand for other forms of
strategic cooperation, for example in purchasing or logistics. Over 80 percent of
those companies responding to a survey
by the business consultants Capgemini
stated that they cooperate with suppliers
in order to make development and production processes more cost-efficient.
However, a desire to protect their own
know-how has made many companies
suspicious of broader strategic partnerships.
Are the desired objectives reached?
Particularly companies which are successful innovators show that many objectives

Importance of partnership with
Component suppliers
5,87
Specialist technical service providers
5,05
System suppliers
5,00
University, technical university
4,10
Other research institutes
3,44
High-tech start-ups/spin-offs
3,29
Competitors
2,38
Not at all important (1)

Very important (7)

Most innovation partnerships are based on an existing customer/supplier relationship.
Source: Capgemini Consulting/University of St. Gallen: “Collaborative Innovation – The
Future of Development Partnerships in Manufacturing Industry”, Berlin/St. Gallen, 2007
(Capgemini 2007) Basis: All 41 companies surveyed

can be achieved through partnerships. In
most cases, these companies have been
able to increase sales and profitability, expand their market share and reduce costs
through partnerships. Furthermore, most
of the companies surveyed were positive
about the future: around three quarters
wish to continue the cooperation with
their partners. The reasons why companies would like to consolidate their partnerships are above all the stronger position relative to their end users and the
knowledge that they can call on the additional resources of their partners.
Partnerships do not run themselves
However, not all development partnerships run smoothly. In around 30 percent
of cases, a planned market launch date
was not achieved despite entering into a
partnership. The greatest problems with
existing partnerships were unclear roles
and areas of responsibility and the increased dependence on suppliers. The
fact that 56 percent of respondents mentioned high coordination costs shows that
attention must also be paid to efficient
management of a partnership.
Looking into the future
In conclusion, innovation partnerships
must be judged by the degree to which
costs can be reduced, intellectual property protected and risks shared. The main
benefit of cooperation is clearly in the
classic areas of engineering, such as initial development, product development
and design. It remains to be seen whether
â&#x20AC;&#x201C; against the background of extreme market conditions â&#x20AC;&#x201C; partnerships will also become beneficial in logistics, production
and assembly.

The main aim of partnership projects is to save money. Long-term objectives play a subordinate role. Quelle: Capgemini 2007

Innovation partnerships
involving companies with

high/ low level of innovation success

Initial development
Market and product development
Design and construction
Sales
Purchasing and logistics
1,1
Production processes
Module and final assembly
0,8
Service
0,6
More intensive
0,3

0,2

50 %

-0,2

0,4
-0,6

-0,4
-0,3

-0,3
Less intensive

-0,3
-0,7
-0,7

-0,7

-0,7

The main emphasis in current partnerships is on classic engineering functions.
Source: Capgemini 2007

Wings, fins and
flexibility
Festoâ&#x20AC;&#x2122;s Bionic Learning Network shows the companyâ&#x20AC;&#x2122;s
commitment to applying natural principles to industrial
practice and to utilising the biomechatronic results of this
process in automation systems. The focus is on completely
new principles of operation that lead to energy-efficient
innovations for the future.

2.2009 trends in automation
Compass 16 17
–

The AquaPenguin shows how underwater technology could look in the
future. These bionic penguins are
autonomous underwater vehicles
which can orientate themselves and
navigate independently in a group.

he most impressive new product
from the Bionic Learning Network – the association Festo has
formed with leading technical
universities, institutes and development
companies – is without any doubt the
FinGripper. This innovative gripper is the
perfect complement to the BionicTripod
and a successful example of how bionic
design principles can be derived from
nature to provide efficient flexible automation. The main distinguishing feature
of the FinGripper is its adaptive grip.
In other words, it adapts its grip to the
object which it is picking up.
Fish fins provide the model
The gripper is based on the FinRay® principle, now being used for the first time
in automation. This principle involves the
reaction between lateral pressure and
counterpressure, similar to the way in
which a fish fin works. If pressure is exerted on a fish’s tailfin, it will move in the
opposite direction to that in which the

The FinGripper – an innovative gripper – is the perfect complement to the BionicTripod and is a successful example of how bionic design principles
can be applied to automation.

force is acting. Thanks to this mode of
operation, FinGripper can even provide an
answer to difficult handling tasks and can
pick up fragile or irregularly shaped workpieces, such as light bulbs, and set them
down safely.
Intelligent, adaptive gripping avoids the
need for complex constructions in handling systems, for example, when sorting
products of different shapes and sizes in
the food industry. FinGripper is also ideal
for pressure-sensitive components which
need to be transported and placed without damaging them. With conventional
grippers, damage to the workpieces being
transported is inevitable. FinGripper, on
the other hand, adapts to the external
shape of workpieces without building
up too much pressure. This means that
BionicTripod and FinGripper can be
adapted to a given application quickly
and easily. The lightweight gripper con-

sumes little energy and does not need
a rigid, heavy-duty mounting – a truly
unique selling point (USP).
AquaPenguin
AquaPenguin and AirPenguin are two
further biomechatronic developments
by Festo. The natural creatures on which
they are based are unusual in the bird
world: they cannot fly but are very agile
in water. The spindle-shaped penguins
have a flow resistance which is 20 – 30 %
lower than that of the most efficient artificial flow body, while their wings are
capable of elastic deformation and develop thrust highly efficiently. These two
factors mean that penguins’ energy
consumption is astonishingly low. This
came to the attention of Festo’s Bionic
Learning Network team, who designed
the AquaPenguins – autonomous underwater vehicles. Just like real penguins,
the mechatronic versions have a flow-

efficient shape. Using their wings and
movable parts of their heads and tails,
they can manoeuvre even in the tightest
of spaces, turn on the spot and swim
backwards, which is something their
biological originals cannot do. Equipped
with 3D sonar, they can communicate
with one another within a group and
also with the outside world and thus
avoid collisions.
AirPenguin
In the course of evolution, penguins
have forgotten how to fly, but the Bionic
Learning Network has managed to teach
the penguins’ artificial relatives how to
do this again. The AirPenguins are autonomous flying creatures with group behaviour. Invisible ultrasound transmitter
stations cover a defined airspace which
the flock of penguins can explore, either
in accordance with defined rules or independently.

2.2009 trends in automation
Compass 18 19
–

BionicTripod

The FinGripper encloses the light bulb like a hand but uses a bionic effect derived from the motion
of a fish’s tailfin.

The working area of a Festo BionicTripod is
several times larger than that of a conventional
Tripod configuration, which means, for example, that pick & place functions with a 90° offset are also possible.

Three glass-fibre rods arranged in the
shape of a pyramid – and made more
rigid by cross braces – form the basis
of the BionicTripod. By advancing or
retracting the rods, the device can be
guided in any direction. The Festo linear axis EGC and servo motor EMMS
ensure that the electrical control and
movement of the device is fast and
precise. It is controlled via the wellproven robotic control software CMXR,
which allows positions to be entered
on a computer instead of mechanically. As a result, the new Tripod is very
light-weight and thus consumes very
little energy.

AquaPenguin and AirPenguin are bionic
models that can have genuine benefits
for automation systems. For example, the
body and tail design of the penguins can
be used in automation as a flexible Tripod
configuration, opening up new applications for handling technology.
Bionics is a true (r)evolution
In the field of automation, factors such
as flexibility, energy efficiency and lightweight relative to the mass to be moved
are becoming ever more important. Nature shows us how we can achieve maximum performance with minimal energy
consumption. With the help of bionics,
Festo is identifying and developing new
technologies to make automation technology even more efficient. Bionic principles have great further potential in
factory automation, for example, for autonomous, flexible, adaptive and selfcontrolling processes. In addition to grip-

per technology, other areas of application
include sensors and closed-loop control
technology. Nature provides the inspiration for the development of decentralised,
self-controlling and self-organising systems. It demonstrates new ways forward
in mechanical engineering.

Mechatronic Motion Solutions

Clever combinations
Pneumatic, electric or servopneumatic, each drive technology has its own advantages and areas of application. A well thought-out combination of all three technologies â&#x20AC;&#x201C; Mechatronic Motion Solutions â&#x20AC;&#x201C; ensures smooth production runs and cost
control. This also applies to the use of linear motor drives.

A comprehensive range of products provides all the required types of motion.

2.2009 trends in automation
Impulse 20 21
–

M

echatronic Motion Solutions
is now making possible what
was previously unfeasible
due to the lack of interfaces
or to incompatible interfaces – namely a
free choice of drive systems and thus a
non-technology-specific automation of
all the types of motion required for components, modules and systems, no matter
what the control system environment is.
All pneumatic and electric drives have the
mechanical, energy and data interfaces to
achieve this. What’s more, matching software packages facilitate reliable dimensioning and configuration, from selecting
individual components to commissioning
complex systems. This means that different technologies can be combined into a
system which not only provides the ideal
solution to a given automation task but
also ensures maximum cost-effectiveness.

uum technology to cover all the types of
motion and almost all the performance
requirements of handling applications:

The right solution for all types of motion
Festo’s comprehensive portfolio of
Mechatronic Motion Solutions features
linear and rotary drives, grippers and vac-

How much value creation do you need?
Mechatronic Motion Solutions supports
customers in their efforts to concentrate
on their core competencies and optimises

• Electromechanical and electrical
positioning systems
• Gantry axes with toothed belt or
spindle drive, cantilever axes
• Scalable motor and controller
combinations
• Complex motion-control solutions
with a wide range of interfaces
• Rotating and swivelling at angles
up to 360°
• Wide choice of designs and performance classes for grippers
• On-site vacuum generation and
suction grippers for all applications
All the above components can be combined easily and flexibly, thanks to uniform interfaces.

their internal processes. Further advantages include the option to buy complete
system packages and to speed up the
time to market.
Make your own ...
Users determine the extent of their collaboration with Festo. They can choose
from standard components, assemblies
and modules and combine these themselves into single or multi-axis systems
with the help of specially designed software tools such as “PositioningDrives”
or FCT software. These allow fast, systematic solutions to be created that fit perfectly and match individual needs. It is of
course also possible to combine individual components, such as a linear drive,
with a motor from another manufacturer.
... or buy a ready-to-install handling
unit?
The alternative to “make your own” is
a fully assembled, ready-to-install and
100 %-tested system produced by Festo
to the customer’s specifications. The
first step is a discussion with Festo;

How linear motors work
In a conventional electric motor (three-phase motor) a ferritic core with defined
poles rotates continuously. Linear motors operate on the same principle, except
that the electrical exciter windings are not arranged in a circle but are stretched
out.
While in a three-phase motor the motion is produced by a rotor, in a linear motor it
is produced by the carriage, which is drawn along the base by a magnetic field. In
theory, a flat-bed linear motor could be created from any electric motor by sawing
it open and rolling it out.

With the linear motor cylinder DNCE-LAS, all the necessary components
such as the linear motor, displacement encoder, guide and reference sensor
are combined to form a ready-to-use axis.

customers can work with Festo experts
to develop an optimum overall solution
and will then receive a detailed quotation.
Once an order is placed, Festo will design
and build an appropriate single or multiaxis system, then test it to ensure that all
the required features are fully functional.
And finally, Festo can also, on request, integrate complete sub-systems directly

Standard
pneumatics

The guided axis DFME- LAS can be easily configured and commissioned
using the Festo Configuration Tool.

into customers’ machines and carry out
commissioning.
Linear motor drives – the acceleration
champions
Among the technological highlights of
Festo’s Mechatronic Motion Solutions are
its linear motor drives. With acceleration
values of 125 m/s, they are ideal for high

Servopneumatics

Toothed belt

dynamics and maximum precision, as required, for example, in the photovoltaics,
medical technology, electronics industries
or for assembly of small workpieces in the
watchmaking industry.
The new electric motor drives ELGL-LAS,
DNCE-LAS and DFME-LAS accelerate at
more than one and a half to four times the

Lead screw

Load
Stroke
Speed
Acceleration
Accuracy
Noise
Rigidity
Costs (TCO)
Flexibility
Performance density
Each drive technology has its specific technical characteristics. Mechatronic Motions Solutions gives users
a free choice of the most suitable axis technology as appropriate to the main requirements of the application.

Ball screw

Linear motor

2.2009 trends in automation
Impulse 22 23
–

“With Festo
linear motor
cylinders, all the
necessary components are
already integrated. All the
user needs to do is install
the cylinders, connect them,
set parameters and give a
start signal – and they’re up
and running!”
Jürgen Kühnle, Product Management Electric Drives

Air bearings with magnetic pretension make the ELGL-LAS precise, more rigid
and insensitive to dry dirt particles. As a result, it is very hard-wearing and
maintenance-free.

rate of other electric and pneumatic
drives. They are also two to three times
more dynamic than electric drives with
screw or belt drive and at the same time
offer an accuracy of 10 μm. This makes
the linear motor axes perfect for applications requiring short assembly times,
since these not only demand high speeds
but also excellent dynamics.
All three linear motor axes are available
as ready-to-use complete systems, including a motor controller SFC-LACI or
CMMP-AS for the free setting of speed,
force and position with various interfaces
such as I/O or a fieldbus interface and
the commissioning software Festo Configuration Tool (FCT). The linear motor axes
incorporate all the necessary components, namely a linear motor, displacement encoder, guide and reference
switch. This means that users only need
to install the complete axes in their applications; laborious assembly of individual
components is no longer required.
Dynamic and precise guidance with
linear motor cylinders
The DNCE-LAS is an electric linear motor
cylinder which has been specially designed for small loads. It allows positioning operations with short strokes in less

than 20 milliseconds. Except for one long
side, all the mechanical interfaces of the
DNCE-LAS are the same as those of the
pneumatic cylinder series DNC. The
guided version, the DFME-LAS, offers
maximum positioning precision and excellent dynamics with small loads. Both
cylinder variants have a guide with an integrated grease reservoir, making them
maintenance-free and giving them a long
service life. Once again, the interfaces are
identical to those of the pneumatic equivalent and thus fit seamlessly with the
Festo modular mechatronic multi-axis
system. This means that hundreds of
freely selectable combinations are possible, both with other electric, pneumatic
and servopneumatic drives and with components for gripping, assembling, rotating
and positioning. Complete, ready-to-install handling systems can also be developed.
Air-bearing axis – motion without
dynamic friction
The flagship of Festo’s linear motor axes
is the air -bearing axis ELGL-LAS. Permanent magnets create a powerful force between the carriage and the base of the
axis. When compressed air is fed between
the magnets and the base, the resulting
air cushion generates a counter-force to

the attraction of the magnets with the result that the carriage is lifted and can
move without dynamic friction. The axis
has excellent dynamics, both when positioned horizontally or vertically. It can be
fitted with several carriages that can
move independently.
The integration of linear motors into the
Festo Mechatronic Motion Solutions system means that users benefit from an optimum relationship between technological
performance and economy, even in applications requiring extremely high acceleration values. When there is a need for extremely high acceleration values of well
over 100 m/s, there is no alternative to
linear motors. The limit for pneumatic
solutions is 30 m/s for pneumatic solutions, 50 m/s for spindle drives and
100 m/s for toothed belt drives.

In Focus Logistics Optimisation

Cutting the cost
of accessories
Tubing, fittings and other pneumatic accessories are seldom at the forefront of usersâ&#x20AC;&#x2122;
minds. They lie out of sight in a store or in maintenance workshops. However, they hide
a considerable savings potential. With tailor-made services from Festo customers can cut
their logistics costs without running the risk of running out of products.

Minimising errors: special labels from Festo with clear illustrations make it
easy to identify products in stores.

2.2009 trends in automation
Impulse 24 25
–

F

esto accessories, such as fittings
and tubing, are not partic-ularly
expensive in comparison with
other components in customers’
stores. However, when these so-called
C materials need to be re-ordered, they
generate the same process costs as A
or B components. Festo is therefore
offering a service package which considerably improves the logistics chain for
accessories and noticeably reduces the
costs of maintaining stocks. The service
includes the planning of optimum order
quantities and ordering frequencies and
the generation of informative stock labels
for a faster, error-free purchasing process.
Festo Logistics Optimisation Service
The Festo Logistics Optimisation Service
consists of three product-support modules which reduce the costs of the purchasing process and maximise its reliability. In a first step, a Festo expert works
with users to determine an ordering history for a particular operational area. Ordering frequencies and order quantities
are identified as well as the range of products involved; then a list is drawn up of
all the products required and the level of
demand for them.
Analysis of ordering behaviour
One of the benefits of this list is that it
significantly reduces the number of products being ordered. Customers can see
at a glance which products are seldom or
never used so that they can either be re-

moved from the ordering portfolio or be
replaced with other products. It is also
possible to optimise order quantities and
ordering frequencies. The following practical example shows the potential savings
on process costs: a customer found that
placing 45 orders, each for six standard
silencers, generated process costs which
were four times higher than for 10 orders,
each for an average of 30 units.
Customer-specific stock labels
The analysis and subsequent optimisation of the range of products ordered and
customers’ ordering behaviour provide
the input for the special Festo stock labels. These show the optimum ordering
quantity for the product in question and
all the data which is of importance for the
customer and Festo. Barcodes make this
data machine-readable. Codes can be
produced in all usual barcode and local
languages, which means that they can be
easily integrated in customers’ existing
stock systems. The labels carry a product
photograph which makes product identification much easier and greatly reduces
the rate of errors.

the Festo Online Shop using a docking
station or a USB interface. This virtually
eliminates the possibility of incorrect
orders. The goods are now ready to be
delivered promptly to customers, who
benefit from a lean, cost-efficient and
error-free ordering process.
This shows how the Festo Logistics Optimisation Service can be used to reduce
the costs and time required for re-ordering accessories. At the same time, the
service ensures that users always have a
stock of those components that they need
at all times in the right quantities and in
the right place. Word is getting around
about these advantages; numerous Festo
customers in Australia, Austria, Belgium,
Finland, Germany, Ireland, Norway,
Poland, Sweden and the USA are now
using this service with great success.

Optimised ordering process
Re-ordering in a stores organised with
Festo stock labels is very simple. A scanner is used to read the barcodes on the
storage boxes of the articles to be ordered. The order number is recorded together with the optimum ordering quantity and this data is then transferred to

Eliminating cost drivers from component stocks: Festo sales engineers work
together with customers to analyse the range of accessories used and the associated ordering behaviour, which helps to reduce purchasing costs.

Immediately: Using a docking station or a USB interface, order
data are transferred from the barcode scanner to the on-line
ordering system.

Safety Technology â&#x20AC;&#x201C; Part 2

Step by step to
greater safety
The countdown has begun. By the end of 2009, every company
in the machine and plant construction sector must implement the
new EU Machinery Directive. It is therefore high time for all those
concerned to know how to implement the Directive. Hazards in
production equipment must be reduced, for example by introducing technical protective measures. In our series of articles,
5
we provide a few ideas on how to implement different types Module
of safety functions.
le
du

4

Mo

le 3
du

Mo

le 2
du

Mo

le
du

1

Mo

This model installation has been divided into five modules and will be used as an example to explain
various safety requirements.

T

his is it: at the end of December
a new EU Machinery Directive
comes into force without a transitional period. The Directive must
be followed by every company which puts
machinery onto the market within the
European Economic Area (EEA). The Directive contains numerous new requirements

2.2009 trends in automation
Impulse 26 27
–

Safety
trigger

What triggers the
safety measure?
For example:
• Approaching a
hazardous point
• Opening a safety
door

Material feed
Support and coating materials are unwound from two rolls and fed to the coating station.

Module 2:

Coating station
The two strips are pressed together by a roller. Coating is carried out using, for example,
the application of heat or adhesive. A further roller completes the bond.

Module 3:

Cutting station
The bonded strips are cut into individual pieces and separated.

Module 4:

Shaping station
The separated pieces of materials are used to produce various shapes with cutter dies.
It would also be possible to print on the workpieces in this station.

Module 5:

Palletising and packing station
A handling system stacks the finished workpieces. Once a stack is complete, it is pushed
towards the packing station. Wrapping foil is placed on the stack by hand, and the stack
is then wrapped automatically, triggered by the two-hand control unit.

for documentation, CE marking and above
all “partly completed machinery”.
The problem now confronting many machine builders is that they cannot be sure
that their present safety measures are
sufficient to meet future requirements.
For example, a risk analysis will have to

be carried out for both complete and
partly completed machines. Design, technical and informative protective measures
must be implemented in order to reduce
risk. The verification of these technical
protective measures often requires extensive calculations. In this second part of
our series of articles on safety technology,

we will provide you with detailed information on ways to reduce risks in modules 3 and 4 of the model installation.
Technical protective measures
The illustration, although by no means
representing all possible hazards, shows
a number of typical hazards which can

Crushing
Impacting
Pulling
Cutting

Exhausting of
system sections

In Module 3 the motions of the drives in the cutting station represent a hazard for the
machine operators.

Safety function â&#x20AC;&#x153;safe exhaustingâ&#x20AC;? as an integrated solution: pre-assembled valve manifold
modules exhaust safety-critical areas of the
system after an emergency stop.

occur in various operating modes. Once
all design measures have been exhausted,
it is the job of the designer to implement
technical protective measures (safety
functions). These are always implemented
in a similar way, i.e. using a sensor, logic
components and outputs.

Stopping, holding,
blocking a movement

Module 4: Vertical motion on a production line often presents a risk of crushing for machine
operators.

Cutting station in the model installation
Within the cutting station, coated plastic
sheets are cut into individual workpieces,
which are then separated. The operator
inputs the size of the pieces to be cut and
a cutter blade on the XY gantry cuts the
material accordingly. This work step represents two potential hazards: cuts and impacts. Firstly, the machine operator could
be injured by the cutter blade as it rapidly
moves back and forth; secondly, the moving XY gantry could lead to impact injuries
on the hands, arms and upper body. The
job of the designer is therefore to define
suitable safety functions and implement
these with the help of EN ISO 13849-1.

2.2009 trends in automation
Impulse 28 29
–

Safe exhausting: the soft-start/quick exhaust valve
MS6-SV is the safety valve of choice when safety
measures for complete processes are required.

Safe exhaust function
How can the required risk reduction be
achieved on this module? One idea would
be to equip the station with a safety guard
with a maintenance door in combination
with an integrated “safe exhaust” valve
manifold. If the maintenance door is
opened, this device, supplied by Festo
as a pre-assembled, fully tested system,
reliably switches the drives to an unpowered state. This would, for example, enable a material jam to be cleared up safely.
A second possibility would be to fit a softstart/quick exhaust valve type MS6-SV
from Festo. This valve has an exhaust rate
of 9,000 litres a minute, 1.5 times the
pressurisation rate, and can exhaust
safety-critical areas of a system after an
emergency stop. The redundant two-channel design of the valve provides singlefault tolerance. This means that the installation will be exhausted safely even if one
fault occurs on the valve. With this solu-

Both the brake unit with cylinder from the DNCKE-S
series and the brake units KEC-S are approved for
use as holding devices and brakes for use in safetycritical control systems.

tion there is no provision within the system to vary the flow rate; this is done
through the valve manifold.
Braking and stopping
Module 4 of the model installation could
be used for a large number of applications, such as printing of the material or
punching out shapes, or as a test station
for the material. A common feature of
all these operations is a vertical motion,
which represents a possible hazard of
crushing. In order to prevent any such
injuries, stations of this kind are often
equipped with a safety function aimed
at “stopping a motion”.
This function could be provided by brake
units and clamping cartridges for the
drives. No matter whether there is an
energy supply failure, stops for maintenance work or a pressure failure or dropout – brake units type KEC-S can brake
and hold the motion of Festo drives within

precisely defined tolerances, using a
clamping component which acts on a
round bar by spring force. The brake units
are able to operate over long periods, can
withstand varying loads and are not affected by fluctuations in operating pressure or leakages.
We will conclude this series of articles in
the next edition of “trends in automation”.
The topics to be covered will include,
among others, safety measures for module 5 of the model installation, a palletising and packing station.

In Focus Tips for greater efficiency

Benefitting from a
partner during a crisis
Particularly in difficult times, it is essential to obtain the maximum benefit from all
business operations. Festo uses ten examples ( 1 to 10 ) to show how it can save its
customers money through best practices, ranging from cost-saving product innovations to software tools and logistics optimisation.

A

ny company which attempts to
fight off the current world economic crisis on its own will soon
find that it is fighting a losing
battle. The way to achieving a stronger
position in this difficult market environment is for companies to ally themselves
closely with partners, suppliers and customers and combine their efforts to optimise processes. Festo has given some
thought to the current market situation
and has developed a comprehensive
range of measures which will enable customers to reduce their costs in real terms
without endangering quality.
Cost-saving product innovations
Festo has developed a whole new series
of products 1 which can genuinely save
process and product costs compared with
conventional products. One example of

this is the new self-adjusting cushioning
(PPS) for pneumatic cylinders. In round
cylinders with PPS, longitudinal slots on
the inside of the cylinders guide the air
away in a controlled way, thus allowing
gentling cushioning right into the end
positions. This design means there no
longer is a need to intervene manually
and thus makes commissioning considerably faster. For example, by using PPS
the commissioning time for a package
sorting machine with 60 stations can be
reduced by as much as five hours.
Innovative materials 2 , for example
the PEN tubing, can also offer considerable savings. Thanks to new material
technology and optimised production
methods, the characteristics of this
tubing are perfect for many automation
applications.

Reducing complexity
Festo is also helping its customers to respond with greater flexibility 3 to rapidly changing customer demands. The
new VB valve series is a good example.
It consists of one basic valve body but
offers a wide choice of configurations for
every application. Customers thus need
to stock only one basic valve body; variants can then be created simply by plugging in the desired configuration.
Festo software tools 4 are a great help
in avoiding overdimensioning. The “PositioningDrives” software package, for example, enables the precise characteristic
load values for electric drives to be calculated quickly and reliably. The design principle of “air to the top”, which caused increased operating costs in many applications, can now be consigned to history.

2.2009 trends in automation
Impulse 30 31
–

Incorrectly specified products
are a waste of time and money:
the dimensioning tools from Festo
(available free of charge) help
users to get it right first time.

One body, many configurations: new valves
from the VB series can be adapted flexibly
to changing needs.

Machine and plant builders can also use
the current recession to achieve technological leads in a way which would not be
possible if they were working at full capacity. For example, now is a good time to
change over to fieldbus technology 5 –
for any company that hasn’t already done
so – without experiencing capacity problems. With its wide range of valve terminals and fieldbus protocols, Festo is the
ideal partner for this type of modernisation, which can cut the costs of wiring and
installation by up to 65 %.
Services and ready-to-install solutions
The Festo Energy Saving Services 6
such as Compressed Air Quality Analysis
and the Condition Monitoring Services
based on the CPX platform help to keep
operating costs under control. What’s
more, ready-to-install solutions 7 are

advantageous as they increase users’
liquidity. With its very wide and graduated
range of products and services 8 , Festo
makes it possible to minimise the process
costs of purchasing and to benefit from
numerous additional services.
As every business area is subject to cost
pressures, there is another Festo service
that will be of interest to many users: the
Festo Logistics Optimisation Service 9 .
Read more about this in the article on
page 24 of this edition of trends in automation.
Targeted training
In times of economic downturn, experience shows that training budgets are
under particular threat. Cutbacks on the
“lawnmower” principle are, however, not
the best solution. After all, it’s precisely

when market conditions are difficult that
companies need to review their processes
and make these more efficient. Training
can play an important role in achieving
this. Festo offers its customer support in
the form of a Training Requirement Analysis Service 10 , which identifies appropriate strategic and efficient training
measures.

The land of windmills: more than
10,000 windmills were in operation
in the Netherlands by the end of the
19th century.

2.2009 trends in automation
Synergies 32 33
–

In Focus Netherlands: Automation in Agribusiness

Small country –
great efficiency
The Netherlands is among the world’s most densely
populated countries. Nonetheless, the country is among
the world’s three largest agricultural exporters. This is
only made through maximum efficiency – both in terms
of machines and equipment and in terms of managing
the credit crunch.

T

he Dutch are extremely logical
when it comes to crisis management. The Netherlands was one
of the first countries to create a
200 billion euro rescue package for its
banks. According to the German foreign
trade agency “German Trade & Invest”,
this puts the “little” Netherlands ahead
even of Germany in the level of support
provided to stabilise markets. Even when
it came to nationalising banks such as
Fortis Nederland and ABN Amro, the
Dutch, normally regarded as free marketeers, were not slow to act. Doing business with Dutch companies therefore
seems to be financially secure for the
foreseeable future.
Special machine construction for agriculture is the segment of the Dutch machine
construction industry which has the highest sales in terms of value (more than 3
billion euros a year); up until the credit
crunch it had an annual growth rate of
5 % in real terms. Activities range from

biotech cultivation and harvesting
through to the factory processing and
packing of foodstuffs.
A broad spectrum
One leading player in the industry is the
Visser Group. With over 40 years’ experience, the company combines modules
such as stacking and destacking systems,
transport and handling systems, packing
machines, palletising units, conveyor systems and encoding and identification systems to form complete units. These units
can be used to process and pack all kinds
of products, such as fruit and vegetables,
mushrooms, fish, meat, cut flowers, beverages, dairy products, confectionery,
bakery products and chemical and pharmaceutical products. The latest example
of enhanced efficiency through automation is a multi-purpose filling machine
for tree nurseries to improve the planting
process using individual pots and trays
(carrier systems for several pots). The
use of automated machinery of this

More than just windmills
Mechatronics is the driving force behind the strong development partnerships between Festo and the Dutch machine
and plant construction industry – and has done so for over
40 years. These partnerships generate creative ideas such
as robotic milking machines or robots for pharmacies. In addition, Festo Netherlands, with its headquarters in Delft, the
home of the Royal House of Orange, also counts many wellknown brands such as Campina, Heineken and Philips among
its customers.
Dutch agriculture represents a vast potential as it accounts
for 20% of the country’s total exports. “Tulips from Amsterdam” is not only a hit tune of yesteryear but also underscores
the fact that the Netherlands is the world’s greatest exporter
of flowers. The sorting of flowers is carried out using automatic handling machines equipped with Festo components.
“Automation also continues to make progress in the cowshed, despite the economic downturn,” explains Thomas
Pehrson, General Manager of Festo Netherlands. Lely is the
market leader in this field, thanks to its reliable milking robot
equipped with a servopneumatic robotic arm able to withstand the harsh environment of a cowshed. Festo was involved in the development of this robotic system right from
the start. In addition to conducting joint product development, Lely also had Festo train its staff in pneumatic
automation technology.

“Despite the economic downturn,
automation in the agricultural industry offers
great opportunities,” explains Thomas Pehrson,
General Manager of Festo Netherlands.

A partnership between Wilee and Festo prevents confusion
when handing out medication in pharmacies. A fully automatic system always picks the right medicine. This jointlydeveloped solution consists of a 3D gantry with electric
toothed belt axes from Festo and includes a manipulator
specially developed by Festo Netherlands.
www.visserite.com
www.lely.com
www.wileetechniek.nl

kind is well worth it, as labour costs in
the horticultural industry are even higher
than the rapidly rising energy costs.
A multi-purpose solution for tree
nurseries
“Like all Visser systems, the multi-purpose filler was the result of an enquiry
from a customer,” says Cees Visser, one
of the company’s senior managers. A
Dutch tree nursery wanted a multi-purpose machine which could plant both
round pots in six-packs as well as trays
of so-called square top round base pots
with box trees. Previously, planting machines had only been able to handle either pots or trays and it was always necessary to reset all the lateral guides,
conveyor belts and drilling stations for
the trays being used. The new development by Visser can do this without the
need for resetting. It unstacks the trays
and then the pots which are to be filled
with earth.

2.2009 trends in automation
Synergies 34 35
–

The machine operates cleanly and uses less potting soil to plant the
seedlings.

Modules in combination: ready-to-install sorting and packing lines for
tomatoes on the vine in accordance with strict HACCP hygiene guidelines.

Multiple tasks
In the next step, a drilling machine makes
planting holes in the earth in the pots into
which a robot then inserts the plants. The
pots and trays are then pushed onto a
conveyor belt, which transports them to
their place in a greenhouse.
The machine operates cleanly and consumes little soil. A brush removes excess
soil from the pots and ensures they are
accurately filled. “With 9 inch pots, our
machine operates to an accuracy of two
grams,” notes Visser. The multi-purpose
filler can handle 650 trays per hours; with
20 pots to the tray, this is 13,000 pots an
hour. According to Visser, no other potting
machine can achieve this speed.
Fewer operators, faster commissioning
The multi-purpose filler requires on average only 2.5 operators: one minds the
machine, one operates a forklift truck and
a “floating” employee fills up the machine
with potting soil or pots. Without automa-

tion, three times the number of operators
would be needed for the same work.
What’s more, the prototype operated
trouble-free after only two days, whereas
a six months’ adjustment period is normally required. It’s thus not only the machine’s operating features but also its
ease of commissioning that make it
highly efficient.
The flexibility of the box tree planting
machine is a good example of the engineering work by the Visser Group. No
matter whether it is for filling, sowing
seeds, planting, sorting using a vision
system or watering, the Visser Group
finds high-performance solutions for
global agriculture across all five continents.
A modular system for individual
solutions
What is Visser’s recipe for flexibility and
success? Visser combines standard machine modules again and again to create

new customer-specific machines. These
incorporate pneumatic valve terminals
MPA from Festo, which are ideal for
Visser’s modular system since they are
themselves modular and can thus be
flexibly expanded, depending on the number of drives and grippers used. Moreover, service units from Festo’s MS series
are also used to ensure that the Visser
machines never run out of air. With this
series, too, the “M” stands for “modular”.
These products are important aspect of
Visser’s system concept.

Packaging and Printing Industry in India

Stronger
than before
“Bad times are bad for many and good for some.”
This quotation from the marketing guru Philip Kotler
can also be applied to the two Indian companies EEL
India and Manugraph. These are among the few companies which are in such a good position that they
may well emerge from the worldwide economic and
financial crisis stronger than ever before.

The model for success: thanks to its “Roto-Packer”, EEL has
quadrupled its sales in two years.

Precise filling: an MFH solenoid valve and a pressure regulator enable EEL customers to fill cement
sacks with exactly 50 kg, even when the air quality
is poor.

2.2009 trends in automation
Synergies 36 37
–

King of the castle – emerging
from the crisis stronger than
before: the offset printing works
from Manugraph.

B

oth EEL Limited, a manufacturer
of packaging machinery, and the
printing machinery manufacturer Manugraph have a market
share of around 90 %, making them real
“kings of the castle” in their home market
of India. They also export large numbers
of machines to emerging and developing
countries in Asia, Africa and Latin America; but it is their strong presence in their
home market which has protected them
from the worldwide economic turbulence
and credit crunch which has affected so
many export-dependent companies.
“Political pressure”
With an electorate of more than 700 million people, India is the world’s biggest
democracy. The political parties themselves generate demand for printed material, since in recent years one party after
another has founded its own daily newspaper. In addition, a parliamentary election campaign lasting several weeks increased demand for newspapers, election
posters and pamphlets. This has meant
that the demand for Manugraph offset
printing machinery on the Indian market
has risen still further in the last few
months.

Pre-assembled solutions: in order to
save time and money, Manugraph more
and more often chooses ready-to-install
pneumatics.

Ready-to-install control cabinets
How has Manugraph reacted to this constantly growing home-market demand?
“By raising the proportion of components
which we outsource to 90%, we have
been able to reduce the throughput time
for a printing machine from six months
to two and a half,” reports Mohan Harshe,
Factory Manager at Manugraph. “It was
of course crucial for us to work with pneumatics partners who were absolutely reliable,” explains Harshe with regard to the
choice of Festo as automation supplier.
Shekhar Shashikant Patil, Area Sales
Manager for the Kolhapur region with
Festo India, describes the manufacturer’s
pneumatics strategy: “Manugraph is
more and more often turning to ready-toinstall pneumatics in order to save time
and money.”

Maximum quality, even in tough
environments
EEL India Limited is enjoying similar success. This manufacturer of packing machines for cement sacks has benefitted
from the Indian construction boom and
was able to quadruple its sales between
2006 and 2008. It built 20 examples of
its highly successful Roto-Packer in 2004.
EEL now supplies 20 machines every 2
months.
In order to ensure that its machines deliver maximum quality even under the
harsh conditions of a construction site,
EEL also selected Festo as its partner.
Chander Sethi, Services Manager at EEL,
describes the advantages of Festo’s pneumatic products: “With an MFH solenoid
valve and a pressure regulator, we are
able to fill cement sacks with exactly 50
kg, even when the air quality is poor.”
And poor air quality is to be expected in
a dusty cement works.

Manugraph India Ltd.
Maharastra, India
www.manugraph.com
Area of activity: offset printing machinery using 4x1 and 2x1 systems
for up to 70,000 pages per hour
(“Smartline” model).

In Focus Injection Moulding of Plastics

Smart
partnerships
Everyone who is looking for smart solutions needs
partners who are ingenious but also reliable. “We
found just such a partner in Festo,” says Christian
Beck, one of the General Managers of Schweizer
Beck Automation AG. This company supplies handling
robots for the so-called in-mould labelling process.

I

n-mould labelling (IML) is a smart
solution for plastic packaging as the
labels are applied to the packaging
while it is being injection moulded.
This saves time and money, since it eliminates the need for rework, subsequent
printing of the packaging, internal transportation and buffer storage. With IML,
labels can be changed without interrupting production. The process is suitable
for both round and square-shaped containers. IML is also flexible with regard
to size: the robots from Beck Automation
can work with containers of up to 40
litres.
The main reason for using in-mould labelling with food packaging is the need
to have an attractive design while also
including bar codes and mandatory information on the packaging.
One work step during injection moulding
The handling robots from Beck Automation pick labels from a magazine using
vacuum grippers and place the complete
labels (for side walls and base) in the
mould cavity. The labels are rolled onto
auxiliary cores outside the tooling before
being transferred to the mould by a handling unit. The labels are positioned in the
mould by static charges and are bonded
at the same time as the packaging is injection-moulded.

With the IML process, the pneumatic functions of vacuum gripping and ejection are
of key importance. “Under no circumstances did we want to use different components for vacuum generation and ejection,” emphasises Christian Beck, one of
the General Managers of Beck Automation AG. The task of a possible pneumatics partner was thus clear: the two functions were to be integrated into one valve.
Two functions – one valve
This application was a spur to Festo to
further develop its VTSA valve terminal
and VSVA valve coils. The VTSA valve terminal combines the advantages of the
compact CPV valve terminal and the modular MPA2 models. “In just six weeks,
we were able to present a solution to
Beck in which two valves were integrated
into one housing,” reports Jochen Krinn,
Festo Product Manager. The VSVA valves
work with two pressure zones and allow
reverse operation.
“Right from the start, we felt we were in
good hands with both the staff of Festo
Switzerland and those of the R&D department at Festo headquarters in Germany,
and we therefore immediately agreed to
act as pilot customers for the new valve,”
says Beck. Festo product specialist Krinn
explains the next step: “We defined the
final product design together with Beck,

Vacuum gripping and ejection: these two functions are both performed by the VSVA valve –
developed in partnership – which is integrated
on a VTSA valve terminal.

Fast and precise: the handling robots from Beck
Automation pick the labels from a magazine with
vacuum grippers and place them (side walls and
base) in the mould.

Clever solution: with in-mould labelling,
labels are wrapped around auxiliary
cores and placed into position in the
mould area by static charges.

after incorporating many of their requests
and suggestions for improvements.” The
former special application product VSVA
on a VTSA valve terminal has now become
a catalogue product from which all our
customers worldwide can benefit.”
More than just pneumatics
“As our business is international, it was
important to us to work with an automation partner whose products are available
quickly and worldwide via a comprehensive network of branch offices,” adds
Beck, describing a further aspect of the
partnership between his company and
Festo. “The future of plant construction
will be decided by customer service.
This is why all our service technicians attended the “Service Ambassador” seminar offered by Festo.” During this seminar,
the Beck service technicians acquired the
necessary communication skills in order
to be able to work confidently with international users and their different approaches. “It is not just a question of
smart solutions, it is also crucial to deliver these to customers in an intelligent
way,” concludes Beck.

Automotive Components Supplier

Tripod for
dynamic handling
â&#x20AC;&#x153;The Tripod needs less space and design time than a handling gantry and is also
faster than a SCARAâ&#x20AC;?. That is how Gerd Ulmer, General Manager of G. Ulmer Automation GmbH, summarises the advantages of the new handling system. He has installed
two Tripod handling units on an assembly machine for the automotive components
supplier.

2.2009 trends in automation
Synergies 40 41
–

High rigidity and low moving mass: the pyramid-shaped, enclosed design makes the robot highly dynamic. At the same time, the handling unit is more
accessible and allows faster production.

O

n a machine which assembles
safety relays for diesel engines,
two Delta robots equip the relay
bodies with seven to nine contacts, depending on the type of relay required. “The components were previously
produced abroad and are now – primarily
in the interests of better quality – to be
produced on a fully automatic machine
which includes automatic test stations,”
explains the client, a special machine
builder. The machine comprises 24 stations and was ordered from Ulmer by a

component supplier to the automotive
industry.
Quality awareness
The machine comprises stations to test
individual components and carry out continuity and high-voltage tests, tests of
soldering flux dosing, monitoring of the
soldering process and measurement of
the contacts fitted to the relay bodies.
“A large number of the assembly cells are
test stations, with four integrated vision
systems,” explains Ulmer.

13 vibration conveyors feed contacts and
other assembly components to the machine. It takes only 90 seconds for the
contacts and semi-finished relay bodies
to pass through all the 24 assembly stations and emerge as fully assembled and
tested relay bodies in a process which
includes spraying the bodies in an injection-moulding machine and printing them
with the date of production. “To be precise, the machine produces four finished
modules every 30 seconds, since that
is how quickly the injection-moulding

Tripod robot system
with CMXR

Precise control: the robotic controller CMXR
positions tools and grippers in three dimensions and forms the basis for the ready-toinstall handling system Tripod.

Thanks to its low moving mass and
the high rigidity provided by the pyramid-shaped, enclosed design, the
robot handling system is highly dynamic but at the same time more accessible than Cartesian handling systems or SCARA robots. The Tripod is
actuated by the robotic controller
CMXR, which is able to position tools
and grippers in 3 dimensions. The tool
tip is guided along the programmed
path at all times, even if the orientation of the tool changes. Operation of
the system is made easier by the optional hand-held terminal, equipped
with a touch screen and keypad. And
what’s more, the controller can be
used, for example, to link in vision
systems such as the intelligent vision
system SBO..-Q and thus also handle
moving objects.

One million relays a year are produced reliably in different shifts using the Delta robot.

machine processes four workpieces,”
says Ulmer, describing the performance
of his machine.
Flexible and with easy teach-in
“It is also thanks to the Tripod that we
have been able to produce around one
million relays a year in three variants,
working in shifts,” reports the system
builder. One of the benefits of the handling system is its flexibility, which is
easy to program using the Festo Configuration Tool (FCT) in combination with
the programming language Festo Teach

Language (FTL). “As we received the revised samples of the workpieces for series production very late from our end
customer and needed to carry out all programming in-house, we found the uncomplicated and intuitive programming of the
robot system very helpful when it came to
modifying the functional sequence and
component-fitting position at short notice.”

Leonardino: the imaginary
cyber-grandchild of the famous
inventor Leonardo da Vinci
The children are having fun trying things out together. Photographs: Stickler Fotografie

At the centre of the activities to celebrate
the 50th anniversary of Festo Austria is
a programme to encourage a new generation of technicians and engineers. Festo
starts with the very youngest schoolchildren. “Leonardino” is the name of a competition for technically gifted schoolchildren aged 8-9 in Vienna. The aim of the
project – for which Festo provided the
schools with pneumatic experimentation
kits – is to interest young boys and girls in

physics and technology. The children enjoyed a journey into a fascinating world
of experience in which they could carry
out experiments to their heart’s content
and through play become familiar with
the phenomenon of air. The finale of the
Leonardino Contest will take place in autumn in Vienna’s Technical Museum.

A complete success
Wolfgang Keiner, General Manager of Festo Austria,
is delighted that this programme has appealed to the
children and won the support of teachers: “It is great
to see the kids at work; their enthusiasm is tangible.
And for teachers it is also an exciting introduction to
the subject of pneumatics.”

Germany/Thailand

VIP visitor
Thai Princess as a guest of Festo
In her home country of Thailand, Princess Maha Chakri Sirindhorn is also called the
“Princess of Technology”. Her great interest in and technical knowledge of new technologies and the ways in which these can be used to bring about improvements in
her country lead her to visit Germany on a regular basis. In July of this year, Her Royal
Highness paid a visit to Festo headquarters in Esslingen.
Asampinpongs Vitoon, General Manager of Festo
Thailand, hands Her Royal Highness Princess
Maha Chakri Sirindhorn a certificate recording the
gift by Festo Didactic of a new technical training
system.

The Princess took part in events in the Festo Technology Centre and in our training department. The main emphasis was on discussions about the latest trends in technical
training. Festo Didactic has been working together with Thai training institutes for many
years. Festo’s largest joint-venture project in Thailand was the Thai German Institute
(TGI), founded in 1995.

Canada

Germany

WorldSkills in Calgary

Environmental
Technology Prize

A meeting point for trainees from all over the world
September 2009 saw the arrival in Calgary of the 850 best trainees from 48
countries and over 51 professions to take part in a competition. Gold, silver and
bronze medals were awarded for every profession – for the best lathe operator,
the best milling machine operator, the best cook, the best EDP specialist ... and
for the world’s best mechatronics and mobile robotics team. Among those at
the starting line were trainees from Festo, who had taken first place in mechatronics during Skills Germany, the national eliminator.
Festo is a founding partner and global sponsor of WorldSkills International. In
addition to the mechatronics competition, which Festo has been supporting
since 1991 as an organiser of this discipline and official supplier of competition
equipment, the company has also been involved in the mobile robotics competition since 2007.

Festo Energy Saving Services
receive award
In June 2009, the Ministry of the Environment of the German state of BadenWürttemberg presented an Environmental
Technology Prize for the first time. The
winner in the “Measurement and Control”
category: Festo Energy Saving Services.
This service enables users to analyse the
energy consumption of installations and
optimise their compressed air consumption. This helps companies to cut their
operating costs and reduce the burden
on the environment.
In her congratulatory speech, Environment
Minister Tanja Gönner explained the jury’s
decision as follows: “Machine construction is a vital part of the economy of
Baden-Württemberg. Festo has recognised the signs of the times and through
its Energy Saving Services is helping to
further extend our international technological leadership to include energy efficiency. A clear gain for the environment
and a worthwhile investment for individual users.”

This year there will surely be a reason to celebrate again – as there was at the WorldSkills
2007 in Japan.

The Environmental Technology Prize is awarded
every two years for outstanding and innovative
products in this field.

The key to success
Saving time and costs in the production of keys
and locks

About this
magazine
trends in automation
2.2009 – December

Precision, speed and efficiency – these were the requirements of Chieh Yung
Automation Corporation for the construction of a new machine for the production of keys and locks.
The company consequently chose the DGSL mini slide, which increases the
cycle times of the machine from 12 to 20 cycles per minute while also ensuring
a high degree of stability and improving capacity. Moreover, repetition accuracy
was enhanced from 0.05-0.1 mm to 0.01-0.03 mm. Replacing the conventional
valve with the VTUB valve terminal, which offers additional pressure sensing,
individual valves and additional valves directly on the terminal, resulted not
only in cost savings with regard to external wiring, but also time and labour
costs for installation, maintenance and operation.
www.cya.com.tw

The usage of modular DGSL pneumatic
drives enhances the efficiency of production
process as well as the stability of product
quality.

The solenoid valve module VB12-SA with
LED extremely meets the customer’s demand of product quality and price

Responsible for content
Dirk Ebertz,
Head of Marketing Instruments
dbrt@de.festo.com
Ralf Sohn, Head of Direct Marketing
rso@de.festo.com
Copyright 2009 Festo AG & Co. KG
All rights reserved.
All images, graphics and texts are covered by copyright or other laws to protect intellectual property. Copying or
modification of contents or their use in
other printed or electronic publications
is permissible only with the express approval of Festo AG & Co. KG.

2.2009 trends in automation
Soft Stop 46

Have you found
some clues,
Mrs. Steinlein?
Fortunately, as head of Festo’s Analysis & Diagnostics department, I am not called upon
to investigate crimes. My department has the
job of thoroughly testing new developments
and special applications with regard to their materials properties. We also study components which have developed faults
in operation in order to find out their causes.
However, a detective’s instinct is necessary. We must scrutinise
components closely, analyse the composition and condition of
their materials and draw conclusions from this. And, just like
a forensic science laboratory, we use the latest technology in
order to do this. With computer tomography, for example, we
can very quickly and reliably examine components and measure
them without the need to destroy them. One of the benefits of
this is a further reduction in the development time for new
products. A vital requirement in a study of material structure
by photo-optical methods is the correct preparation of a microsection of the material concerned. The way a sample is taken
must be appropriate to the purpose of the study. With our latest
tool, a gas chromatography mass spectrometer, we can detect
even extremely low levels of contamination in a component.
It is also very important for us to have information which is as
precise as possible on the environment in which a component
is used. In the case of special applications, we clarify in advance
whether the intended material and design are suitable for the
specific operating conditions. We may need to make on-site visits if the conditions are particularly difficult. For example, for an
agricultural customer, we took measurements of the ammonia
content of the air in the cowshed. Customers benefit from our
work twice over: our analyses help Festo to develop products
even faster and match them perfectly to a specific customer’s
operating conditions, making the products more reliable. And
if faults still occur, we can determine the causes of them quickly
and precisely. This enables us, for example, to draw the customer’s attention to the fact that a particular grease or cleaning
agent is not ideal for the product concerned and offer an appropriate solution.
Our conclusions are of course also incorporated into product
development. Our 20 staff members in the analysis section
carry out 800 to 1000 analyses every year and make the results
available throughout the company worldwide. That way we ensure not only that any current problems are solved but also
that Festo products fulfil customers’ requirements ever more
precisely.”

Working together to stay on course
In sailing, every action must be just right in order to tack successfully and for the boat to stay in the wind. Every crew member knows what he or she has to do. Everyone knows that he or
she can rely on the others. Trust and reliability are vital, not only
at sea but also when industrial companies work together to
drive projects forward. Particularly in difficult times partnerships
can help to keep companies on course. The yacht in the picture
is from the legendary J-class which dominated the Americaâ&#x20AC;&#x2122;s Cup
in the 1930s. This boat, too, has survived many storms â&#x20AC;&#x201C; as well
as the hands of time. After being laid up in 1938, it was restored
in the 1980s and celebrated its comeback to the high seas.